Shipping case alternative

ABSTRACT

A new way of shipping cartons and other packages so as to minimize the cost and the resource used. In one embodiment, the invention comprises the use of two or more films shrink wrapped about the packages which are juxtaposed to form a unit. At least one of the films is opaque and at least one of the films is clear. The opaque film is sufficiently resistant to the transmission of light such that UPC bar codes present on the individual packages cannot be read through the film by bar code reading machines. The shrink wrap in place about the unit may include one or more gripping openings.

BACKGROUND OF THE INVENTION

[0001] In the present business environment, there is unremittingpressure to reduce costs and conserve resources in the manufacture ofproducts. Not insubstantial is the amount of resource devoted topackaging and shipping of products such as detergent cartons. Often suchproducts will be shipped in a shipping case made of corrugatedfiberboard.

[0002] Brown et al., U.S. Pat. No. 5,992,630 discloses a packagedproduct which includes a plurality of cartons, a corrugated board ofpaperboard carrier wall disposed along a portion of the periphery, andshrink wrapping. The shrink wrap film has vent holes that arespecifically sized and spaced apart as needed to provide adequateventing of one or more of the volatiles from the shrink wrappedmultipack. While the Brown et al. invention does not require a fullshipping case, it still utilizes corrugated board or paperboard as thecarrier wall for the multipack.

[0003] Oberle, U.S. Pat. No. 5,002,782 discloses perforated heatshrinkable thermoplastic bags wherein slits cut by a knife blade reducethe splitting when a product such as a meat product is cooked within thebag. The perforations permit escape of moisture and prevent ballooningand collection of moisture which could leave to uneven cooking. Theslitting is preferably done by a v-shaped knife blade. The bag ispreferably formed from a seamless tube of thermoplastic material.

[0004] Limousin, U.S. Pat. No. 4,586,312 discloses a heat shrinkablepackage with a frangible access panel defined by perforations. Aperforation cylinder may be used.

[0005] Truchiya et al., U.S. Pat. No. 5,067,612 discloses a shrink filmpackage having a perforated folded strip. A perforation wheel may beused. A notch for tearing off may be provided.

[0006] Harris, U.S. Pat. No. 4,815,603 is directed to a shrink wrappackage having vent openings to permit free air flow through the packageand allow the escape of gas. The shrink wrap plastic cover is shrinkwrapped to a container by means of a heat gun.

[0007] Doyle, U.S. Pat. No. 5,171,593 discloses a method of wrapping atray of produce or other articles requiring ventilation. The methodinvolves use of a sheet of flexible plastic film having a perforatedportion. Micro perforations are arranged in rows and columns. The priorapproach of randomly placing perforating needles around a cylinder pressand applying the cylinder to the film is said to have resulted ingenerally ragged perforations which will cause the film to tear as it isstretched over the tray.

[0008] Britt et al., U.S. Defensive Publn. T900,020 discloses a shrinkwrap package wherein portions of the seam adjacent the ends of thearticle form tear tabs.

[0009] Heider, U.S. Pat. No. 4,333,570 discloses an opaque shrinkwrapped packaging having finger slits terminating in semi-circular cuts.

[0010] Kirby, U.S. Pat. No. 3,442,436 discloses an easy opening meansfor a package which comprises a pair of seams curved in a film likemember wherein free ends of the tab means are pulled relative to thepackage, the tab means cause the film like member to tear along thepaths.

[0011] Cutrara, U.S. Pat. No. 4,289,237 discloses a firewood packagehaving a film of plastic material secured around a generally curvedsurface of a bundle wherein the plastic material is perforated to permitair to circulate into and through the bundle. The portions of theperforations illustrated in the figure are shown as being in twoparallel arcs.

[0012] Becker, U.S. Pat. No. 3,403,779 discloses an opening device for apackage wherein the device is used to sever an elongated strip from thematerial.

[0013] Fales, U.S. Pat. No. 4,306,653 discloses a packaging containerfor protection of fragile articles during shipping and storage whichincludes an outer carton and plurality of inner packing support panelsattached to the contained article by a heat shrinkable film. Theillustrated film appears to have perforations.

[0014] George, U.S. Pat. No. 5,201,403 discloses a packaging systemusing a shrink wrapping material with weakenings.

[0015] Harris, U.S. Pat. No. 4,941,572 discloses a package for shippingand storing articles, such as cut flower arrangements. A plastic filmvented shell is disposed about the flowers and connected to a containerin shrink wrap relation. The package includes a U-shaped insert. Aplurality of openings 60 are present of a size and a number to permitair flow through the shell in a shrunk condition.

[0016] Anderson, U.S. Pat. No. 3,804,235 discloses a package comprisingan article having heat shrinkable material wrapped therearound. Thesheet of heat shrinkable material has at least one opening. A thickeningridge defines a reinforcement which prevents tearing. A plurality ofarticles may be disposed in juxtaposed position within the package. Theopenings may be, e.g., for placement of a tax stamp on cigarettes or forcarrying the package as in FIG. 10.

[0017] Ganz, U.S. Pat. No. 3,756,397 discloses use a single wrap of asingle sheet of continuous shrinkable and bondable plastic material toconstitute virtually the entire package for a cluster of plural likecontainers such as beverage containers. Finger access openings such as25-26 are provided in the plastic sheet in the upper side of thecontainer.

[0018] Worley, U.S. Pat. No. 4,971,197 discloses a shrink wrappedpackage with a tear strip.

[0019] Other patents involving shrink wrap packaging or other forms ofpackaging include Coons, U.S. Pat. No. 3,416,288, Begnaud, U.S. Pat. No.3,589,510, Oglesbee, U.S. Pat. No. 3,693,788, Becker et al, U.S. Pat.No. 3,338,404, Whittington et al., U.S. Pat. No. 3,764,351, Yamashita etal., U.S. Pat. No. 5,240,111, Forman, U.S. Pat. No. 3,456,780, Heier,U.S. Pat. No. 4,254,869, Rumsey, U.S. Pat. No. 3,026,656 and Brown, U.S.Patent No. RE 27212.

[0020] Roth, U.S. Pat. No. 4,119,202 discloses a selectively rupturableshrink wrapped package.

[0021] Prior to the discovery of the present invention, of the inventorsherein learned a shrink wrapped package of five cartons of detergenttablets was being sold in Europe wherein the shrink wrapped cartons wereprepared by shrink wrapping a single clear film about the five cartonsand heat sealing the film closed at the bottom of the cartons. Openings,which were a result of the process by which the shrink wrap wasattained, were present at each end of the combined cartons/shrink wrap.The cartons were made of paperboard.

[0022] EDL, can pack brochure received by one of the applicants hereinon Nov. 27, 2000, discloses an “easy open perforated tear strip option.”Film perforations for easy-open packs are mentioned as an option. Packscan be trayless and can be “bullseye”.

SUMMARY OF THE INVENTION

[0023] The invention is directed to the discovery of a new way ofshipping cartons and other packages so as to minimize the cost and theresource used. In one embodiment, the invention comprises the use of twoor more films shrink wrapped about the packages which are juxtaposed toform a unit. In this aspect of the invention at least one of the filmsis opaque and at least one of the films is clear. The opaque film issufficiently resistant to the transmission of light such that UPC barcodes present on the individual packages cannot be read through the filmby bar code reading machines. Since the unit which comprises thecombined packages will typically have its own bar code, (eg., aseparate, outer label), use of the opaque film prevents the bar codereading machine from inadvertently reading one of the bar codes for theindividual packages and thereby falsely crediting the manufacturer withshipment only of an individual package rather than the multi-packageunit. Typically, the two or more films will be heat sealed to eachother.

[0024] In accordance with another aspect of the invention, the shrinkwrap in place about the unit includes one or more gripping openings.These openings may be naturally formed during the shrinking of the filmsor they may be formed by cutting openings in the film. In accordancewith a preferred embodiment of the invention, the gripping openings areformed on opposite ends of the unit, and the unit is shipped with theopaque film on top (eg., cartons inverted). Because the opaque film islikely to be the unperforated of the two films, this will minimizedamage to the integrity of the film when the unit is lifted duringshipping.

[0025] In accordance with another embodiment of the invention, theinvention is directed to a combination of two or more packagesjuxtaposed to form a unit wherein the unit is shrink wrapped in two ormore films on opposite sides of the unit and at least one of the filmsincludes a single line of zipper perforations extending along one of thefilm sides and gripping apertures in at least one film side on oppositesides of the perforations. By “film side” is meant one of the sides ofthe unit from which a shrink wrap film is imposed and which unit side iscompletely covered by said one film, except for any perforations orother openings in that film. This arrangement permits the shrink wrapunit to be readily grasped and readily opened along the zippingperforations. By zipper perforations, it is meant that the perforationsare arranged in sufficient proximity to one another linearly and spacedsufficiently from each other laterally to permit the shrink wrap film toopen along the perforations by creating tears between the perforationsupon application of reasonable manual force. The pattern of perforationsis such that the perforations are opened like a zipper along theintended line of perforations.

[0026] In accordance with another embodiment of the invention, a unitcomprising two or more juxtaposed packages is shrink wrapped in two ormore films on opposite sides of the unit and at least one of the filmsincludes zipper perforations in the film in a side intermediate the filmsides and parallel to a longitudinal axis of the unit. Preferably, thesingle line of zipper perforations on each side of the unit extend froma gripping opening on one end of the unit perpendicularly to the planeof one of the film sides, across each heat seal side parallel to thelongitudinal axis of the unit and then perpendicularly again to theplane of the film side until it reaches a second opening on the otherend of the unit. By this arrangement, it is possible readily to tearopen the shrink wrapped unit by application of reasonable manual force.The heat seal sides are the sides wherein the two films are heat sealedtogether.

[0027] In accordance with yet another embodiment of the invention, aunit comprising two or more juxtaposed packages is shrink wrapped in twoor more films on opposite sides of the unit, preferably one opaque andone clear, and at least one of the films includes a tear strip definedby spaced zipper perforations in the film along two parallel lines in atleast one of the film sides parallel to a longitudinal axis of the unit.Preferably, the tear strip extends from a gripper opening on one end ofthe unit perpendicularly to the plane of one of the film sides, acrossthe film side parallel to the longitudinal axis of the unit and thenperpendicularly again in the plane of the film side until it reaches asecond opening on the other end of the unit. By this arrangement, it ispossible readily to tear open the shrink wrapped unit by application ofreasonable manual force.

[0028] For a more complete understanding of the above and other featuresand advantages of the invention, reference should be made to thefollowing description of the preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029]FIG. 1 is a perspective view of a unit of juxtaposed packageshaving a film positioned for shrink wrapping above one film side of theunit and a film positioned for shrink wrapping below another film sideof the unit.

[0030]FIG. 2 is a perspective view of a unit of juxtaposed packagesafter shrink wrapping in accordance with an embodiment of the invention.

[0031]FIG. 3 is a perspective view of a unit of a juxtaposed packagewhich has been shrink wrapped in accordance with a second embodiment ofthe invention.

[0032]FIG. 4 is a perspective view of a unit of juxtaposed cartons whichhas been shrink wrapped in accordance with a further aspect of theinvention.

DETAILED DESCRIPTION OF THE INVENTION

[0033] In FIG. 1, unit 10 wherein cartons 12 and 14 are juxtaposed sideby side has positioned above it clear shrink wrap film 16 and positionedbelow it opaque shrink wrap film 18. Films 16 and 18 are made of a lowdensity polyethylene or LDPE/HDPE blend and are heat shrinkable. Thethickness of sheet 16 is preferably from 0.001″ to 0.005″, especiallyfrom 0.002″ to 0.004″. The thickness of sheet 18 is preferably from0.001″ to 0.005″, especially from 0.002 to 0.003″, most preferably0.003″ for each. Preferably film 18 is made opaque by adding (TiO₂)titanium dioxide colorant to the resin.

[0034] Film 16 is shrink wrapped from one side of unit 10, the top sidein FIG. 1. Unit 18 is shrink wrapped from an opposing side, from thebottom in FIG. 1. As seen in FIG. 2, shrink wrapping of the filmsresults in a film side for the unit on each side on which the film fullycovers the side of the unit. In the case of film 16, film side 30 iscreated, as seen in FIG. 2. In the case of film 18, film side 32 iscreated on the bottom of the unit, as also indicated in FIG. 2.

[0035] Heat sealing of the two films from opposite directions results increation on each of the opposite ends of the unit of a “bullseye” whichmay be used as a gripping openings 34 and 36. Films 16 and 18 are heatsealed along a periphery of unit 10, excluding the bullseye, alongperimeter heat seal 40. Extending from gripping opening 34 to grippingopening 36 first perpendicular to film 30 then parallel to alongitudinal axis of unit 10 and then again perpendicular to film side30 to bullseye 36 are zipper perforations 44 (FIG. 2). Zipperperforations are designed such that reasonable manual force applied tothe shrink wrap will split open the shrink wrap along the perforationsas a result of tears extending from one perforation to the next and soon. On either side of zipper perforations 44 are gripping openings 50,52.

[0036] Typically, bottom film 18 will not be provided with perforations.

[0037] In operation, preferably, unit 10 is shipped with opaque film 18(opaque film side 32) as the upper end. In this way when the unit isgripped at bullseye 34, 36 and force is inherently extended upwardly,there are no perforations to prematurely open the shrink wrap. Rather,in accordance with one aspect of the invention, the unit is shipped withopaque film side 32 as the upper end, which has no perforations, and thepackage is inverted when it is time to open the shrink wrap. The shrinkwrap is then readily opened by applying manual force upwardly at thebullseye 34, 36 and/or at gripping apertures 50, 52.

[0038] In a second embodiment, illustrated in FIG. 3, zipperperforations 60, 62 extend on each side of the unit between bullseyes34, 36. The zipper perforations preferably extend on the first bullseyeend to and along each heat seal side and then to the second bullseyeend. Again, it is advantageous for the unit 10 to be shipped with opaqueheat seal side 32 as the top of the unit and to invert the package andapply reasonable manual force e.g., at the bullseye, to open the zipperperforations when it is time to display or use the cartons.

[0039] The embodiment of FIG. 4 is similar to the previous embodimentsexcept that the perforations are present in the form of tear strip 70defined by two parallel lines of perforations extending from grippingopening 34 across the clear heat seal side 30 to gripping opening 36. Inthis embodiment, as in the others, the unit 10 is preferably shippedwith opaque film 18, opaque heat seal side 32 as the top of the unit tominimize the chances that when the unit is lifted during shipping theperforations will prematurely tear open. When it is desired to open theunit, the unit is inverted and reasonable manual force is applied at thegripping openings 34, 36 to tear open package at the tear strip.

[0040] A particular advantage of one aspect of the present inventionresults from the use of the opaque film as the bottom half of the shrinkwrap. The opaque film obscures to a bar code reader the bar codes whichmay well be present on the bottoms or bottom sides of the packages. Itis desirable that the bar code readers read the bar codes for the wholeunit e.g., on the outside of the shrink wrap rather than the individualpackages. If a bar code reader picks up a bar code inadvertently for anindividual package the manufacturer may not receive credit for havingsupplied the full multipack unit. Use of the opaque bottom film servesto minimize the possibility of an errant reading from the bar codereaders.

[0041] Preferably the opaque side includes no perforations since itpreferably serves as the top side of the unit. If perforations werepresent in the opaque side, then upward force experienced by the opaqueside during shipping when the bullseye gripping openings are graspedcould result in premature opening of the shrink wrap.

[0042] Preferably, the packages of the unit are cartons and morepreferably, the cartons are corrugated as at 82 of carton 80 of FIG. 2.This enhances the shrink wrap unit compressive strength, notwithstandingthe absence of a shipping case or a sleeve of paperboard or corrugatedmaterial within the shrink wrap.

[0043] There may be difficulties in applying more than one line ofperforations by the manufacturer of the film. Where such is the case, asecond line of perforations may be applied, for example at thefacilities of the end product manufacturer, with a star wheel or thelike. Where gripping openings are present in the clear heat seal side,on opposite sides of the perforations, it may be desirable to includeJ-shaped cuts to ensure that in the event that a small tear occurs itdoes not spread to other parts of the shrink wrap.

[0044] Where cartons are used as a package, they may be made frompaperboard or, more preferably as indicated above, corrugatedfiberboard. The shrink wrapping films may be applied by conventionalmeans such as heat sealing the leading edge (in the cross direction),pushing the cartons against the sealed edge with the films top andbottom, then sealing the trailing edge (CD), and then finally passingthe bundle through heat tunnel equipment to form a tight heat-sealedbundle.

[0045] It should be understood of course that the specific forms of theinvention herein illustrated and described are intended to berepresentative only, as certain changes may be made therein withoutdeparting from the clear teachings of the disclosure. Accordingly,reference should be made to the following appended claims in determiningthe full scope of the invention.

What is claimed is:
 1. A combination of two or more packages juxtaposedto form a unit, said unit being shrink wrapped in two or more films onopposite film sides of said unit, wherein at least one of said films isopaque and at least one of said films is clear.
 2. The combination ofclaim 1 wherein said shrink wrapped films include a pair of grippingopenings, said openings being disposed at opposite ends of said unit,said ends being other than said film sides.
 3. The combination of claim1 wherein said films are heat sealed to each other on at least twoopposite heat seal sides of said unit, said heat seal sides beingintermediate said at least two film sides.
 4. The combination of claim 1further comprising a single line of zipper perforations extending in atleast one of said films at least along one of said film sides.
 5. Thecombination of claim 4 further comprising gripping openings on oppositesides of said perforations in said film side.
 6. The combination ofclaim 1 wherein at least one said opaque film is at least 1 mil. thickerthan said at least one clear film.
 7. The combination according to claim1 wherein at least one said opaque film has a thickness of from 1 to 5mils (thousands of an inch) and at least one said clear film has athickness of from 1 to 5 mils.
 8. The combination of claim 1 wherein oneof said films includes a tear strip defined by spaced zipperperforations in said film along two lines at least partially parallel toa longitudinal axis of said unit.
 9. The combination of claim 2 whereinone of said films includes a tear strip defined by spaced zipperperforations in said film extending between said gripping openings alongtwo lines extending partially in one of said film sides parallel to alongitudinal axis of said unit.
 10. The combination of claim 1comprising zipper perforations in said shrink wrap on each heat sealside extending parallel to a longitudinal axis of said unit.
 11. Thecombination of claim 2 further comprising zipper perforations in saidshrink wrap extending from one of said openings to the other, partiallyextending through each heat seal side parallel to a longitudinal axis ofsaid unit.
 12. The combination of claim 1 wherein said packages arecartons.
 13. The combination of claim 12 wherein said cartons arecomprised of corrugated fiberboard, said corrugations extending in adirection perpendicular to a longitudinal axis of said unit andperpendicular to a plane of one of said film sides.
 14. A process forshipping a combination of two or more packages juxtaposed to form aunit, said unit being shrink wrapped in two or more films on oppositesides of said unit, comprising shipping said unit, one of said filmsbeing opaque and another not being opaque, the unit being shipped withthe opaque film side as the top side of the combined packages and shrinkwrap.
 15. The combination according to claim 1 wherein said unit is notcontained within a shipping case.
 16. The combination according to claim1 wherein said unit comprises from 2 to 4 packages.
 17. The combinationaccording to claim 12 wherein said packages are cartons.
 18. The processaccording to claim 14 wherein the non-opaque film includes zipperperforations and the opaque film lacks zipper perforations.
 19. Thecombination according to claim 2 further comprising a line of zipperperforations extending from one of said openings to the other andextending through one of said film sides, and further comprising opposedgripping apertures on opposite sides of said line of perforations onsaid film side.
 20. A combination of two or more packages juxtaposed toform a unit, said unit being shrink wrapped in two or more films on filmsides of said unit, said film sides being on opposite sides of said unitand including a line of zipper perforations along one of said filmsides, said unit further comprising gripping apertures on opposite sidesof said line of perforations in said film side.
 21. The combination ofclaim 20 wherein said side zipper perforations are in a film which isclear to a UPC bar code reader.
 22. A combination of two or morepackages juxtaposed to form a unit, said unit being shrink wrapped intwo or more films on opposite sides of said unit, one of said filmsbeing non-opaque and including a tear strip defined by zipperperforations in said film along two lines spaced in at least one of saidfilm sides parallel to a longitudinal axis of said unit, the other ofsaid films being opaque.
 23. The combination of claim 22 wherein saidshrink wrapped films include gripping openings at opposite ends of saidunit and said tear strip further extends along two lines perpendicularto said longitudinal axis from said openings to said film sides.
 24. Thecombination of claim 20 wherein said packages comprise cartons and saidcartons are made of corrugated fiberboard, said corrugations extendingin a direction perpendicular to a longitudinal axis of said unit andperpendicular to a plane of one of said film sides.
 25. The combinationof claim 22 wherein said packages comprise cartons and said cartonscomprise corrugated fiberboard, said corrugations extending in adirection perpendicular to a longitudinal axis of said unit andperpendicular to a plane of one of said film sides.
 26. The combinationof claim 21 wherein said film in which said perforations are placed is aclear film, clear to UPC bar code readers.
 27. The combination accordingto claim 1 having at least one line of perforations as an openingdevice.
 28. The combination of claim 9 wherein said tear strip extends90% of the length of said film side.
 29. The process according to claim14 wherein said opaque film side is not perforated.
 30. A process forshrink wrapping a package comprising shrink wrapping a film havingzipper perforations about a package and then imposing a second set ofzipper perforations upon said shrink wrapped package.